AMP Research Powerstep 77158-01A User manual

www.amp-research.com 1/13 IM77158 rev 02.02.16
INSTALLATION GUIDE
3-5 Hours
Professional installation recommended
Invented, engineered and manufactured exclusively by AMP Research in the USA. May be covered by one of the following patents:
6,641,158; 6,830,257; 6,834,875; 6,938,909; 7,055,839; 7,380,807; 7,398,985; 7,584,975 ©2012 AMP Research. All rights reserved.
Printed in USA.
TOOLS REQUIRED
qSafety goggles
qMeasuring tape
q10 mm socket
q13 mm socket
q1/2” socket
qRatchet wrench and extension
qWire crimpers
qWire stripper / cutter
q3/16” hex key wrench (allen wrench)
q4mm hex key wrench ( allen wrench )
qElectrical tape
qWeather proof caulking (silicone sealer)
qSilicone spray
INSTALLATION TIME
12 3 4
SKILL LEVEL
4= Experienced
AMP RESEARCH TECH SUPPORT 1-888-983-2204 (Press 2) Monday - Friday, 6:00 AM - 5:00 PM PST
APPLICATION AMP Part #
Ram 1500 Crew Cab 2009-2012 77158-01A
Ram 2500/3500 Crew Cab 2010-2012 77158-01A
5-Year Limited Warranty
WARRANTY
Note:The application works only on the Crew Cab model Vehicles.

www.amp-research.com 2/13 IM77158 rev 02.02.16
AMP RESEARCH POWERSTEPT M – R a m C r e w C a b
CAUTION: HANDLE WITH CARE.
To ensure our customers receive all components with full integrity, we pack
the motors separate from their linkage assemblies. This requires that the
installer position and fasten the motor before continuing with the install.
Please follow the instructions below and handle the assembly carefully.
CAUTION: Dropping the assembly or any excessive impact MAY cause
damage to the motor.
Instructions:
1. Position the gear cover in place as shown if not already in place.
2. Seat motor into position on the three mounting bosses. This may require
an adjustment of the gear by moving the swing arms.
3. After seating into place, fasten the motor with the three motor mount
screws with 4mm Hex Head. Tighten screws to 36 in-lbs (4N-m). Do not
over torque.
INSTALLATION GUIDE
Attaching motor to Linkage assembly.
EXPLODED VIEW
80-03129-90 Motor
19-03179-90 Socket cap screw
19-03133-90 Washer
19-03138-90 Drive Gear Housing Cover

www.amp-research.com 3/13 IM77158 rev 02.02.16
AMP RESEARCH POWERSTEPT M – R a m C r e w C a b
1x2
Running board assembly
D
B
(A) End cap left (x1)
(B) End cap right (x1)
(C) T-nut insert (x2)
(D) Socket cap screw (x2)
(E) End cap wedge right (x1)
(F) End cap wedge left (x1)
A
CE
F
Cut Dimension
4
Motor Linkage assembly
Passenger
6
Wire harness
5
Idler Linkage assembly
x2
7
A06 Controller
8
Posi-Tap™
x4 9x16
M8 Hex Bolt w
Conical washer
2
Rail Assembly
x2
3
Motor Linkage assembly
Driver
5/16-18
Flange Nut
10 x12
11 x6
M5 Hex Bolt

www.amp-research.com 4/13 IM77158 rev 02.02.16
AMP RESEARCH POWERSTEPT M – R a m C r e w C a b
Socket Cap Screw
15 x8
Cable tie (11”)
25 x2
Cable tie (7”)
24
x20
26
LED Lamp
x4
14 x4
5/16 Flange Bolt
12
M5 Washer
x6
27
Butt Connector
x8
13 x4
M6 Flange Bolt
Upper Mount
Spacer
22 x4
5/16-18
Carriage Bolt
16 x8
1/4-20
Flange nut
17 x8 18 x8
Rivet Nut
21
Reinforcement Bracket
x4 23
Blind Rivet
x4
19 x8
Button Head Torx
Screw
20 x8
Washer
28
Rivet Nut Tool

www.amp-research.com 5/13 IM77158 rev 02.02.16
AMP RESEARCH POWERSTEPT M – R a m C r e w C a b
29
LED Light Bracket
x4
5/16-18
Carriage Bolt
16 x8
34
Linkage Mounting
Bracket Driver
36
Rail Mounting
Bracket Driver
x2
31
Motor
30 x2
Gear Cover
33
Linkage Mounting
Bracket Passenger
35
Rail Mounting
Bracket Passenger
32
Drill Templates
(Driver & Passenger)
x2
DRIVER SIDE
Use template to drill out pinchweld
holes if not already present on
vehicle. Pilot drill the two
appropriate holes as indicated
below. Front linkage marked
"Front" and Rear Linkage
marked "Rear". Center punch
and drill to 1/8". Then drill holes
to 9/32". Be sure to tape the
template flush to sheet metal
to ensure proper placement.
Rear
Front
Forward
TAPE
TAPE
TAPE
TAPE
TAPE
TAPE
BEND DOWN
BEND UP
BEND DOWN
BEND DOWN
BEND UP

www.amp-research.com 6/13 IM77158 rev 02.02.16
AMP RESEARCH POWERSTEPT M – R a m C r e w C a b
Driving Assembly
Idler Assembly
Front
HARDWARE MOUNTING
OVERVIEW
(passenger side shown)
Locate forward most and
rearward most mounting
provisions on inner sill of truck.
Remove tape from sill drain hole
at both mounting points.
NOTE: Driving Linkage Assemblies
(with motor) mount in the front; Idler
Assemblies mount in the rear.
Assemble Hex Bolt (lubricated with soapy water),
Washer, Rivet Tool, and Rivet Nut together as
shown and place into hex cutouts in sill. An extra
Hex Bolt and M8 Washer is supplied to install rivet
nuts.
Set Reinforcement Plate in place and locate with
rivet nuts. Drill hole using an 1/8” drill bit. After
drilling apply paint to prevent rusting
Once hole is drilled insert a piece of string or wire
through hole in Reinforcement Plate. Set plate into
position.
Set rivet nuts into place for alignment. Insert pop
rivet through hole in plate and secure in place. Once
pop rivet is installed remove string or wire from
Reinforcement Plate. NOTE: Verify plate is pulled
flush to the body before securing pop rivet.
1
2
4 5
3

www.amp-research.com 7/13 IM77158 rev 02.02.16
AMP RESEARCH POWERSTEPT M – R a m C r e w C a b
Once rivet nuts are in place use a screwdriver to
push back tab in hole to avoid interference with
linkage mount.
With Rivet Nut Tool held in place with 19mm wrench,
tighten Hex Bolt until Rivet Nut deforms and secures
itself to the sheet metal (110 in-Lbs. or 4 turns).
Remove Hex Bolt and Rivet Nut Tool. Repeat for
each of the four mentioned mounting locations.
NOTE: Hold Rivet tool with
wrench while loosening bolt.
WARNING: Rivet
Nuts not properly
collapsed will not
hold securely to
sheet metal.
Fold both the passenger and driver side templates in
the proper direction noted on the template. Thread in
hex bolts and slide slots in template up to bolts. Next
use tape and apply tape on all surfaces on template
that is labeled “Tape”. Start at Hex bolts and make
sure template is flat on each surface. Work your way
down and out.
Mark appropriate holes as indicated with a center
punch. Front linkage marked “Front” and Rear
linkage marked “Rear”.
Front
Rear
Using a marker draw cross hatch to verify bit does not
walk while drilling.
Pre drill hole using an 1/8” drill bit. Next drill holes
to 9/32”. Debur all surfaces. NOTE: Filing of hole
may be required if drill bit wandered. After drilling
apply paint to prevent rusting.
Tape can be applied to
this surface to prevent the
template from shifting.
9
9
NOTE: Models with holes in Pinch Weld Skip to Step #12
67
8
10
9
11

www.amp-research.com 8/13 IM77158 rev 02.02.16
AMP RESEARCH POWERSTEPT M – R a m C r e w C a b
Insert and position Carriage bolts (16) into slot on rail (4). Insert from either end of rail. Using Flange Nuts
(17) provided assemble rail to Brackets onto the rail. Next install Flange Bolt (14) and Flange Nut (17) onto
bracket tab. Driver side shown. Dimensions shown are for reference. Torque flange nuts to 16ft-lbs.
Install Brackets onto vehicle. On Passenger side install Rear Rail Mounting Bracket (35) and Front Linkage
Mounting Bracket (33) using the Hardware provided. 4 Conical washer bolts (9), 4 Button Head Torx (19),
washers (20) and Flange Nuts (21). Once bolts are tightened up to vehicle torque Conical washer bolts (9) to
16 ft-lbs and Button head Torx to 6ft-lbs.
Note: Badge on rail sits towards the rear of the vehicle!
12
13

www.amp-research.com 9/13 IM77158 rev 02.02.16
AMP RESEARCH POWERSTEPT M – R a m C r e w C a b
8
Thread supplied bolts 2x (9) into Front Drive Linkage.
Repeat step for Rear Idler Linkage. Do not tighten.
8
14
19
Install provided spacer (22) and M6 bolt (13) into
upper mount as shown on both the Drive and Idler
linkages. Do not tighten.
Slide mounting T-nut into position, Center board in
rail pocket. Tighten fasteners to 10 ft-lbs.
Using a 13mm socket Torque linkage bolts 4x (9) from
step 3 to 16 ft-lbs. Next use a 10mm socket, torque
linkage spacer bolt 2x (13) from step 6 to 8 ft-lbs.
Once linkages are tight cycle board to verify steps
deploy under own weight.
13
16
Attach motor to linkage. Using a 4mm hex Torque
to 36 in-Lbs.
9
13
23
9
13
14
17
Once linkages are tightened to the bracket tighten
bracket tab Flange bolt (14) and Nut (10). Torque to
16 ft-Lbs.
15
1
16
5
18
14
1
17
1
19

www.amp-research.com 10/13 IM77158 rev 02.02.16
AMP RESEARCH POWERSTEPT M – R a m C r e w C a b
23
Prepare large tie-wraps for mounting Power Step
Controller. Loosely loop tie-wraps around large
bundle of wires behind battery in engine
compartment.
14
Insert controller into tie-wrap loops and cinch down
securely. The tie-wraps should cinch down into
channels on controller surface.
5
Remove fuse from Power Step Wire Harness.
4
Connect power leads from Controller, Red to
positive battery terminal and Black to the vehicle
body ground as shown.
4
Insert Tighten
Strip 3/8” Insert and
Tighten
Splice Power Step trigger wires into the Door
Ajar wires with provided Posi-TapTM splicers. The
Power Step trigger wires color coordinate with the
factory Door Ajar wires. Follow the steps below to
correctly splice wires.
21
1
22
5
24
20
25
Route the trigger wires of Power Step Harness
(Purple wires) down toward the fuse box located in
front of the battery.
4

www.amp-research.com 11/13 IM77158 rev 02.02.16
AMP RESEARCH POWERSTEPT M – R a m C r e w C a b
5
29
27
1
28
5
30
26
5
31
Remove fuse box lid and fuse box power lead with
13mm wrench. While depressing release tabs, lift
fuse box to view bottom side.
Locate and remove Black Connector with Gray
latch on bottom side of fuse box (labeled “G” where
connected to fuse box).
Locate the vehicle’s Door Ajar Switch wires on
the removed connector as indicated in chart and
diagram below according to vehicle model year.
CAVITY CIRCUIT FUNCTION
1 - -
2 - -
3 - -
4 - -
5 F941 20PK IGNITION RUN/START
CONTROL OUTPUT
6 - -
7 - -
8 N4 20DB/WT FUEL LEVEL SENSOR
SIGNAL
9 - -
10 W7 20BR/GY WIPER PARK SWITCH
SENSE
11 - -
12 L91 22WT/BR HAZARD SWITCH
SENSE
13 L51 18WT BRAKE LAMP SWITCH
OUTPUT
14 G75 22VT DRIVER DOOR AJAR
SWITCH SENSE
15 G74
22VT/WT
PASSENGER DOOR
AJAR SWITCH SENSE
16 G77 22VT/GY LEFT REAR DOOR
AJAR SWITCH SENSE
17 G76 22VT/YL RIGHT REAR DOOR
AJAR SWITCH SENSE
18 - -
19 - -
20 - -
21 - -
22 - -
23 - -
CAVITY COLOR FUNCTION
VIOLET
VIOLET /
WHITE
VIOLET /
GRAY
VIOLET /
YELLOW
11
12
16
14
CAVITY CIRCUIT FUNCTION
1 - -
2 - -
3 - -
4 - -
5 F941 20PK IGNITION RUN/START
CONTROL OUTPUT
6 - -
7 - -
8 N4 20DB/WT FUEL LEVEL SENSOR
SIGNAL
9 - -
10 W7 20BR/GY WIPER PARK SWITCH
SENSE
11 - -
12 L91 22WT/BR HAZARD SWITCH
SENSE
13 L51 18WT BRAKE LAMP SWITCH
OUTPUT
14 G75 22VT DRIVER DOOR AJAR
SWITCH SENSE
15 G74
22VT/WT
PASSENGER DOOR
AJAR SWITCH SENSE
16 G77 22VT/GY LEFT REAR DOOR
AJAR SWITCH SENSE
17 G76 22VT/YL RIGHT REAR DOOR
AJAR SWITCH SENSE
18 - -
19 - -
20 - -
21 - -
22 - -
23 - -
CAVITY COLOR FUNCTION
VIOLET
VIOLET /
WHITE
VIOLET /
GRAY
VIOLET /
YELLOW
14
15
16
17
Model Year
2011- 2012
CAVITY CIRCUIT FUNCTION
1 - -
2 - -
3 - -
4 - -
5 F941 20PK IGNITION RUN/START
CONTROL OUTPUT
6 - -
7 - -
8 N4 20DB/WT FUEL LEVEL SENSOR
SIGNAL
9 - -
10 W7 20BR/GY WIPER PARK SWITCH
SENSE
11 - -
12 L91 22WT/BR HAZARD SWITCH
SENSE
13 L51 18WT BRAKE LAMP SWITCH
OUTPUT
14 G75 22VT DRIVER DOOR AJAR
SWITCH SENSE
15 G74
22VT/WT
PASSENGER DOOR
AJAR SWITCH SENSE
16 G77 22VT/GY LEFT REAR DOOR
AJAR SWITCH SENSE
17 G76 22VT/YL RIGHT REAR DOOR
AJAR SWITCH SENSE
18 - -
19 - -
20 - -
21 - -
22 - -
23 - -
Model Year
2009- 2010
CAVITY CIRCUIT FUNCTION
1 - -
2 - -
3 - -
4 - -
5 F941 20PK IGNITION RUN/START
CONTROL OUTPUT
6 - -
7 - -
8 N4 20DB/WT FUEL LEVEL SENSOR
SIGNAL
9 - -
10 W7 20BR/GY WIPER PARK SWITCH
SENSE
11 - -
12 L91 22WT/BR HAZARD SWITCH
SENSE
13 L51 18WT BRAKE LAMP SWITCH
OUTPUT
14 G75 22VT DRIVER DOOR AJAR
SWITCH SENSE
15 G74
22VT/WT
PASSENGER DOOR
AJAR SWITCH SENSE
16 G77 22VT/GY LEFT REAR DOOR
AJAR SWITCH SENSE
17 G76 22VT/YL RIGHT REAR DOOR
AJAR SWITCH SENSE
18 - -
19 - -
20 - -
21 - -
22 - -
23 - -
4
15
With Posi-Taps securely in place, carefully replace
connector and drop wire bundles and fuse box
back into place. Reattach fuse box power lead that
was removed in previous step.
Insert Tighten
Strip 3/8” Insert and
Tighten
Splice Power Step trigger wires into the Door
Ajar wires with provided Posi-TapTM splicers. The
Power Step trigger wires color coordinate with the
factory Door Ajar wires. Follow the steps below to
correctly splice wires.
Route the two Wire Harness legs down over the
wheel wells toward Motor Linkages, long leg
across to the passenger side. Secure harness with
tie wraps.
4

www.amp-research.com 12/13 IM77158 rev 02.02.16
AMP RESEARCH POWERSTEPT M – R a m C r e w C a b
Affix LED light bracket assembly to rail. Mount front
light rearward of front linkage and mount rear light just
forward of rear linkage.
Affix LED lamp (20) to LED Bracket (22) as shown..
5
35
Using supplied butt connectors, connect the lamp wires. Red to Red, Black to Black. Once Crimped use
heat gun to shrink tube. Close and wrap conduit with electrical tape. Secure all loose wires with cable ties.
Pull lamp wires upward to avoid any wire snagging.
On driver side, run Wire Harness leg down and along
underside of the vehicle floor and frame to front Drive
Linkage. Connect harness to motor and secure harness
with tie wraps. Route remainder of wire harness towards
rear linkage assembly for LED lights
On Passenger Side, run Wire Harness leg down and along
underside of the vehicle floor and frame to front Drive
Linkage. Connect harness to motor and secure harness
with tie wraps. Route remainder of wire harness towards
rear linkage assembly for LED lights
4
33
1
34
5
36
32

www.amp-research.com 13/13 IM77158 rev 02.02.16
AMP RESEARCH POWERSTEPT M – R a m C r e w C a b
-
AMP RESEARCH POWERSTEPT M – R a m C r e w C a b
Reinstall Fuse and check that all doors activate the Power Step and the LED Lights work when
doors open and close. Reinstall any remaining trim panels.
CORRECT OPERATION OF LIGHTS: All four lamps will illuminate upon opening any door of vehicle. Lamps
will stay on until restowing of both Power Steps or until 5 minutes has expired with the doors open. When the
lights timeout after 5 minutes, they can be reillumintated by closing and opening any door of vehicle.
FINAL SYSTEM CHECK
Check that all doors activate the PowerStep and the LED lights work when doors open and close.
NORMAL OPERATION: When the doors open, PowerStep automatically deploys from under the vehicle.
When the doors are closed, PowerStep will automatically return to the stowed/retracted position. Note that
there is a 2-second delay before the PowerStep returns to the stowed/retracted position.
4
37
37

Automatic power deploy:
The running boards will extend down and out when the doors are opened.
Automatic power stow:
The running boards will return to the stowed position when the doors are closed. There will be a 2-second
delay before the running boards move to the stowed position.
Automatic stop:
If an object is in the way of the moving running board, the running board will automatically stop.
To reset, clear any obstruction, then simply open and close the door to resume normal operation.
Manually set in the deployed (OUT) position for access to the roof:
your foot while at the same time closing the door. To resume normal operation, open and close the door.
Maintenance: In adverse conditions, debris such as mud, dirt, and salt may become trapped in the running
board mechanism, possibly leading to unwanted noise. If this occurs, manually set the running boards to
Avoid spraying the motors directly. After washing, apply silicone spray lubricant to the hinge pivot pins.
Do not apply silicone, wax or protectants like Armor All® to the running board stepping surface.
Caution! Keep hands away when the running board is in motion.
™Congratulations on your purchase of the
genuine AMP Research PowerStep!
Here’s what you should know...
AMP RESEARCH warrants this product to be free from defects in material and workmanship for FIVE (5) YEARS FROM
DATE OF PURCHASE, provided there has been normal use and proper maintenance. This warranty applies to the original
purchaser only. All remedies under this warranty are limited to the repair replacement of the product itself, or the repair
or replacement of any component part thereof, found by the factory to be defective within the time period specied. The
decision to repair or replace is wholly within the discretion of the manufacturer.
for instructions. You must retain proof of purchase and submit a copy with any items returned for warranty work. Upon
completion of warranty work, if any, we will return the repaired or replaced item or items to you freight prepaid. Damage
to our products caused by accidents, re, vandalism, negligence, misinstallation, misuse, Acts of God, or by defective parts
not manufactured by us, is not covered under this warranty.
ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR A PARTICULAR PURPOSE CREATED HEREBY ARE
LIMITED IN DURATION TO THE SAME DURATION AND SCOPE AS THE EXPRESS WRITTEN WARRANTY. OUR COMPANY SHALL
NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGE.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental
or consequential damages, so the above limitations or exclusions may not apply to you. This warranty gives you specic
legal rights, and you may also have other rights that vary from state to state.
FOR WARRANTY ISSUES WITH THIS PRODUCT PLEASE CALL AMP RESEARCH CUSTOMER SERVICE 1-888-983-2204
5-YEAR LIMITED WARRANTY
WARNING
Be sure to read and precisely follow the provided instructions when installing this product. Failure to do so could place the vehicle
occupants in a potentially dangerous situation. After installing or reinstalling, re-check to insure that the product is properly installed.
AMP Research PowerStep running boards automatically move
when the doors are opened to assist entering and exiting the vehicle.